Engine, Removing, Biturbo Engine

WARNING: This page is about a different car, the 2015 Audi A7 Quattro and 2014 Audi A7 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools And Workshop Equipment

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Special Tools And Workshop Equipment Required

Pry Lever 80-200
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor Lift Table VAS 6131B with Scissor Lift Table - Audi Set VAS 6131/10, Scissor Lift Table - A8 Set VAS 6131/11 and Scissor Lift Table - Q7 Set VAS 6131/13
Shop Crane - Drip Tray VAS 6208
Hose Clip Pliers VAS 6362

Special tools and workshop equipment required

Hose Clip Pliers VAS 6340

Fig 2: Identifying Hose Clamp Pliers
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Procedure

NOTE:

With lock carrier installed, engine is removed downward with transmission and subframe.

During installation, cable ties must be installed at the same location.

WARNING:

When working on the whole exhaust system:

Follow the safety precautions when working on the exhaust system, refer to EXHAUST SYSTEM SAFETY PRECAUTIONS .

WARNING:

Risk of vehicle tipping over with engine removed.

Secure vehicle. Luggage compartment must be empty for this.

There is a risk of injury because the fuel is under very high pressure.

Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.

-- Position the front wheels so they are straight.

CAUTION:

Danger of causing damage to electronic components.

Observe the steps for disconnecting the battery.

-- Turn off the ignition.

-- Disconnect the ground cable from the battery terminal, refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover -arrows-.

Fig 3: Identifying Engine Cover

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-- Empty the coolant circuit, refer to A/C System with Refrigerant R134a.

-- Remove the lock carrier cover, refer to LOCK CARRIER COVER, REMOVING AND INSTALLING Front Bumper .

Fig 4: Identifying Coolant Reservoir Cap

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WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.

-- Remove the cap -arrow- from the coolant reservoir.

-- Remove the left and right front wheels, refer to WHEELS AND TIRES .

-- Remove the front left and right wheel housing liners, refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the front left and right wheel spoilers, refer to FRONT WHEEL SPOILER, REMOVING AND INSTALLING, AUDI A7/S7 .

-- Remove the noise insulations, refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Remove the right air intake grille, refer to AIR INTAKE GRILLE, REMOVING AND INSTALLING, AUDI A7/S7 THROUGH MY 2014 or AIR INTAKE GRILLE, REMOVING AND INSTALLING, AUDI A7/S7 FROM MY 2015 .

-- If equipped, remove the right cover -1- to do this release the catches -arrows-.

Fig 5: Identifying Cover

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NOTE:

Collect escaping coolant in a clean container for disposal or reuse.

Fig 6: Identifying Drain Plug

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-- Place the Shop Crane - Drip Tray VAS 6208 under engine.

-- Remove the drain plug -1- and drain the coolant.

-- Lift the clip -2- and disconnect the coolant hose from the radiator.

-- Loosen the clamp -arrow-, remove the coolant hose from the left lower coolant pipe and let the coolant drain out.

Fig 7: Identifying Coolant Hose Clamp

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-- Remove the right coolant hose from behind, lift the clamp -arrow-, and drain the coolant.

Fig 8: Identifying Hose Connection

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-- Remove the plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and air guide -1-.

Fig 9: Identifying Bolts & Air Guide

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-- Remove the bolts -arrows- and the air guide -2-.

Fig 10: Identifying Bolts

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NOTE:

Ignore -item 1-.

-- Open the clamps -arrows- and remove the air guide pipe -1-.

Fig 11: Identifying Air Guide Pipe & Clamps

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-- Disconnect and free up the connector -2- from the Mass Airflow Sensor -G70-.

Fig 12: Identifying Air Filter Housing

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-- Remove the air filter housing -1- upward.

Fig 13: Identifying Hose Clamps

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CAUTION:

There is a risk of contamination.

Follow the guidelines for cleanliness when working on the fuel supply system, refer to CLEAN WORKING CONDITIONS .

-- Loosen the clamps and remove the fuel hoses.

Blue fuel hose
Yellow fuel hose
White fuel hose

-- Open the clamp -1- and remove the coolant hose.

Fig 14: Identifying Clamps

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-- Loosen the clamp -2- and remove the vacuum hose.

-- Loosen the clamp -arrow- and remove the coolant hose from the coolant pipe.

Fig 15: Identifying Clamp

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-- Loosen the clamp -3- and remove the air guide hose.

Fig 16: Identifying Clamp -3-

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NOTE:

Ignore -items 1 and 2-.

-- Disconnect Vacuum Hose -arrow-.

Fig 17: Identifying Vacuum Hose -Arrow-

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-- Open the clamp -2- and remove the coolant line.

Fig 18: Identifying Bolts

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-- Remove the bolts -1- and free up the refrigerant lines.

Fig 19: Disconnect Connector For A/C Compressor Regulator Valve

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CAUTION:

Risk of damaging refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove bolt -2-, remove the refrigerant line from the A/C Compressor and set aside.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

NOTE:

Ignore -items 1 and 3-.

-- Disconnect the connector -2- for Charge Air Pressure Sensor -G31- / Intake Air Temperature Sensor -G42- and free up the wire.

Fig 20: Component Location Charge Air Pressure Sensor - G31- / Intake Air Temperature Sensor -G42-

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NOTE:

Ignore -item 1-.

Vehicles with an SCR system:

Fig 21: NOx Sensor -G295- Component Location

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-- Remove the NOx Sensor -G295- -arrow- free up and set to the left side.

Continuation for All Vehicles:

-- Remove the tower brace, refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Release the retainer -arrow A- and open the cover -arrow B-.

Fig 22: Identifying Retainer

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Vehicles without an SCR system:

Fig 23: Identifying Fasteners

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-- Remove the nuts -2, 3 and 4- and free up the wire.

-- Remove the connector -1- from the bracket and disconnect it.

Vehicles with an SCR system:

Fig 24: Identifying Bolts

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-- Remove the nuts -2 and 3- and free up the wire.

-- Remove the connector -1- from the bracket and disconnect it.

-- Remove the bolts -arrows- and then remove Terminal 30 Wire Junction 2 -TV22- from the plenum chamber bulkhead.

-- Disconnect the connector -arrows- on the Catalytic Converter Heating Control Module 1 -J1021- and free up the wiring harness.

Fig 25: Identifying Connectors

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Continuation for All Vehicles:

Fig 26: Identifying Foam Wedge & Bolts

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-- Move the foam wedge -1- to the side.

-- Remove the bolts -arrows-.

-- Remove the nut -2- on the right longitudinal member and free up the ground wires.

Fig 27: Identifying Retainer -Arrow-

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-- Unlock the retainer -arrow-, open the wiring duct -1- and free up the wiring harness.

-- Remove the bolts -arrows-, pull the filler tube -1- out of the windshield washer fluid reservoir and out of the opening in the body and move it to the right.

Fig 28: Identifying Bolts

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-- Remove the cap nut -2- and free up the ground cable.

Fig 29: Engine Control Module -J623- component location

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-- Open the retainer -arrow- and remove the Engine Control Module -J623- -1- from the bracket and move it to the side.

-- Remove the bolts -arrows- and the cover -1- from the plenum chamber E-box.

Fig 30: Identifying Cover -1- & Bolts -Arrows-

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-- Disconnect the connectors -1- and remove the nut -2- for the wire.

Fig 31: Identifying Connectors And Nut

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-- Release the retainers -arrows- and remove the relay carrier with the fuse panel -3-.

-- Disengage the engine wiring harness from the plenum chamber E-box and free it up.

-- Release the retainers -A arrows- and remove the wiring bushing -1- upward -arrow B-.

Fig 32: Identifying Wiring Bushing

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-- Lay the wiring harness on the engine and secure the Engine Control Module -J623- so that it cannot fall.

-- Disconnect the coolant fan connectors -1, 2- to do this, push the clamp to the rear -arrow- and push the release down.

Fig 33: Identifying Connector

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-- Free up the wiring harness.

NOTE:

Ignore -item 3-.

-- Remove the air guide hose from the air guide pipe by loosening the hose clamp -arrow-.

Fig 34: Removing Air Guide Hose From Right Air Guide Pipe And Lay It Aside By Loosening Hose Clamp

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-- Remove bolts -arrow-, Press stop -1- for the torque support towards the engine.

Fig 35: Identifying Bolts

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-- Disconnect the connector -arrow- from the left and right front speed sensors -G45- / -G47-.

Fig 36: Identifying Speed Sensor Connector

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-- Disconnect the left and right connector -1- from the front vehicle level sensor -G78- / -G289- and free up the wire -arrow-.

Fig 37: Identifying Left And Right Connector

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-- Remove the brake caliper and secure the brake caliper with the brake hoses still attached inside the wheel housing with wire, refer to BRAKE SYSTEM - MECHANICAL COMPONENTS .

CAUTION:

Risk of damaging brake pistons.

Do not operate brake pedal when the brake caliper is removed.

-- Remove the nut -2- and the bolt -1-.

Fig 38: Identifying Nut And Bolt

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-- Remove the upper control arm upward from the wheel bearing housing -arrows-.

-- Repeat the procedure on the other side of the vehicle.

-- Remove the left and right stabilizer bar bolt -1-.

Fig 39: Identifying Left And Right Stabilizer Bar Bolt

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-- Remove the left and right nuts -3-.

NOTE:

The bolts -2- will be removed later.

-- Remove the steering intermediate shaft from the steering gear and the push the splines together, refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Free up the clip -arrow-.

Fig 40: Identifying Connector

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-- Disconnect the connector -1- and free up the wire.

-- Remove the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

CAUTION:

The suspension components could be damaged.

Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.

-- Remove the left and right bolts -arrows- and the heat shield -1-.

Fig 41: Identifying Subframe Heat Shield Bolts

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-- Remove the propshaft, refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .

-- Release the safety catch -arrow-, push the retainer down and disconnect the connector from -2- from the Power Steering Control Module -J500-.

Fig 42: Identifying Connector -1-

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-- Disconnect the connector -1- from the Power Steering Control Module -J500-.

-- Free up the wiring harness.

-- If installed, remove the bolts -arrows- and then remove the heat shield.

Fig 43: Heat Shield Bolts

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-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.

Fig 44: Identifying Selector Lever Cable

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-- Press the lock washer -2- off and remove the selector lever cable from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Disconnect the connector -arrow-.

Fig 45: Identifying Connector

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NOTE:

If the Engine and Transmission are to be separated, remove the connectors from the bracket.

Vehicles with an SCR system:

Fig 46: Identifying Clip, Connector & Metering Line

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-- Disconnect the connector -2- and free up the wire.

-- Loosen the clip -1- and free up the Reducing Agent Injector -N474- with the metering line -3- on the tunnel crossmember and tie up to the underbody.

Prepare scissor lift platform:

Fig 47: Identifying Scissor Lift Platform VAS 6131

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-- Equip the Scissor Lift Table VAS 6131B with the Scissor Lift Table - Audi Set VAS 6131/10 and Scissor Lift Table - A8 Set VAS 6131/11, and VAS 6131/13 as follows:

Platform coordinates	Components from the Scissor Lift Table - Audi Set VAS 6131/10, Scissor Lift Table - A8 Set VAS 6131/11 and Scissor Lift Table - Q7 Set VAS 6131/13
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6			/13-2
F8+H8	/13-5			/13-2
B14	/10-1	/10-4	/10-5	/10-7
G14	/10-1	/10-4	/10-5	/11-1

-- First manually secure the mounting elements to the scissor lift table.

-- Position the Scissor Lift Table VAS 6131B horizontally.

Note bubble level (sight glass) on support platform.

-- Guide the Scissor Lift Table VAS 6131B under the engine/transmission subassembly.

Fig 48: Identifying Subframe Bolts (Tighten To Specifications)

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WARNING:

The subframe could cause an accident if it is not secured.

Do not loosen the subframe bolts -2- and -3-.

-- Remove the left and right subframe bolts -1-.

-- Attach mounting elements from the VAS 6131/10 and VAS 6131/13 at the left and right on the front of the subframe as shown in the illustration.

Fig 49: Attach At Left And Right Front Of Subframe As Shown In Illustration

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-- Ensure threaded spindles are completely installed.

-- Attach the mounting elements from the VAS 6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Fig 50: Attach At Left And Right Front Of Subframe As Shown In Illustration

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-- Position mounting elements from the Scissor Lift Table - Q7 Set VAS 6131/13 at the lower left and right on the wheel bearing housing as shown in the illustration.

Fig 51: Attach At Lower Left And Right Of Wheel Bearing Housing As Shown In Illustration

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-- Attach mounting elements from the Scissor Lift Table - Audi Set VAS 6131/10 and Scissor Lift Table - A8 Set VAS 6131/11 at the left and right rear of the tunnel crossmember, as shown in the illustration.

Fig 52: Identifying Mounting Elements

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-- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.

-- Attach mounting element base plates to Scissor Lift Table VAS 6131B and tighten to 20 Nm.

-- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.

Fig 53: Identifying Subframe Bolts (Tighten To Specifications)

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-- Remove the left and right subframe bolts -2- and -3- in a diagonal sequence in stages.

-- Remove the bolts -arrows- on the tunnel crossmember.

Fig 54: Identifying Tunnel Crossmember Bolts

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-- Remove the left and right bolts -2-.

Fig 55: Identifying Left And Right Stabilizer Bar Bolt

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CAUTION:

Risk of damaging hose and wiring connections as well as engine compartment.

Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
Carefully guide the engine/transmission sub-assembly with subframe out of engine compartment while lowering.
Carefully guide the suspension struts past the longitudinal members.

-- Lower engine/transmission assembly.

-- Remove the Scissor Lift Table VAS 6131B with engine/transmission assembly from under the vehicle.